Process Re-Validation Record

Date 16-Dec-11 DOE # 24/11

Process Adhesive Printing Performed By Mateen, Ravi
M/C # SP-6 Sushil kumar Rawat
Part A: Installation Qualification
Enclose installation report of the equipment listed above. Mention if the installation by done by supplier or by Fusion

Installation Report : Enclosed (done by supplier)

Supplier Details : ATMA CHANP ENT.CORP.
Operator Trained: Sushil kumar Rawat, Ravi

PART B: Operational Qualification

all control variables, toggle switches, emergency buttons in the parameter column.
ese parameters as per manufacturer's spec. Verify if the controls are operable at the given ranges.

Parameter M/C Range Working

Main Power button (MCB) On/Off Working
Air Pressure Valve On/Off Working
M/C Main Switch On/Off Working
Squeezee(FW) Button(Green) Push Working
Squeezee(RV) Button(Green) Push Working
Sclaper(UP/Down) Button (Green) Push Working
Squeezee Pressure(UP/Down) Button(Green) Push Working
Table(FW/RV) Button(Green) Push Working
Conveyor Button(Green) Push Working
Vaccume Button(Green) Push Working
Screen(UP/Down) Button(Green) Push Working
Squeezee (Stop/ Start)Button(Green) Push Working
Frame Lock Button(Green) Push Working
Frame Tight Button(Green) Push Working
Screen Setting Button(Green) Push Working
M/C Off Button Green Working
M/C On Button(Green) Yellow Working
Table(FW) Manual Button Red Working
Vaccume Manual Button Yellow Working
Auto Knob (Green) Verified Ok
Conveyor Knob (White) On Working
Squeezee Speed Rotate Knob Button 0-10 Verified Ok
Sclaper Speed Rotate Knob Button 0-10 Verified Ok
Conveyor Speed Rotate Knob Button 0-10 Verified Ok
Counter 0-999999 Verified Ok
Vaccume Manual setting Display-2 0-999 Verified Ok
Auto Dial for table setting 0-1 Verified Ok
Screen Setting Counter Value Manual-4 0-9999 Verified Ok
Vaccume Controller Knob-2 0-6 Verified Ok
Screen Setting Off Contact Counter Value manual 0-99999 Verified Ok
Squeezee pressure manual Button Red Working
Sclaper Pressure manual Button Red Working
Peeloff Pressure manual Button Red Working
Squeezee Pressure gauge-2 0-10 bar Verified Ok
Sclaper Pressure gauge-2 0-10 bar Verified Ok
Vaccume Pressure Gauge 0-1 Mpa Verified Ok
Squeezee Pressure Setting gauge-2 0-15mm Verified Ok
Sclaper pressure Setting gauge-2 0-15mm Verified Ok

Form No.:FI/QF/38 Page 1 of 1 Rev date : 03/05/2010

Form No.:FI/QF/38 Page 1 of 1 Rev date : 03/05/2010
Part C: Performance Qualification

Process / Product Characteristics matrix

Major Product Characteristics

Panel stickness on screen

Main Process

Glue Thickness
Mis registration
Parameters

Voids / Gaps

Uniformity
Bleed

Not sharp squeegee edge will cause variation in Glue

1 Squeegee Edge S P deposit & bad print quality.
High Pressure will cause Bleed near the open pads while
Squeegee Pressure P S
2 low pressue will result in gaps / voids
High print speed will result in thick Glue deposits while low
3 Print Speed S P print speed cause low thickness of Glue.
4 Scraper Speed P High scraper speed lead to gaps.

5 Off Contact P S P Increase in off contact will resul in bleed & mis registration.

6 Pinning P Not proper pinning will result in mis-rgistration.

Manufacturer's Recommendation for Process Parameters

No specific reccommendation from manufactur's side.

Experiments must be conducted to choose the right operating ranges for equipment under validation
The starting point for process parameters must be based on one or more of the following;-
1. Manufacturer's recommendation
2. Fusion experience with similar product/ process
3. Other Technical resources (internet, books, expert opinion etc)

The experiments must be conducted by varying one parameter & keeping other parameters
constant. The results of varied parameter level should be documented.
And the experiment repeated for all significant parameters.

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Fusion already has a long experience with Screen printing process & Imaging process.
Hence only a few variables are chosen for DoE, rest of the parameters shall be as per supplier TDS.
1 Squeegee Pressure
2.Print Speed
3. Off contact

Product on which experiments are being done is BMW / Audi Stiffner with following
material config:
Base Aluminium, Panel Area 410mm x 248mm, Al Thickness 1.0mm
Panel Area 510 mm X 270 mm
Experiment 1
Constant Parameters
Print speed 3 mm/sec, Scraper speed 2 mm/sec , Off - Contact 0mm

Squeegee
Pressure Results
0.5 Thickness of adhesive is not uniform,Gaps observed ( Not acceptable)
0.8 Thickness uniform but , slight gaps observed ( Not acceptable)
1 Uniform thickness observed , no gaps / voids seen ( Acceptable)
2 Uniform thickness observed , no gaps / voids seen ( Acceptable)
2.5 Uniform thickness observed , no gaps / voids seen ( Acceptable)
3 Uniform thickness observed , blees observed at some area. ( Not acceptable)

Experiment 2
Constant Parameters
Squeegee pressure 1 Bar, Scraper speed 2 mm/sec, Off-contact - 0mm

Print Speed Results

2 mm/sec Thickness less than 25 micronobserved ( Not acceptable )
2.5 mm/sec Thickness with in the range , Adhesive layer uniform ( Acceptable)
3 mm/sec Thickness with in the range , Adhesive layer uniform ( Acceptable)
3.5mm/sec Thickness with in the range , Adhesive layer uniform ( Acceptable)
4 mm/sec Adhesive not cured while curing operation,thickness more than required(Not acceptable)

Experiment 3
Constant Parameters
Squegee pressure 1 Bar, Print speed 3mm/sec, Scraper speed 2mm/sec

Off-Contact Results
0mm Best Result (Acceptable)
0.5 mm Best Result (Acceptable)
1mm Best Result (Acceptable)
1.5mm Bleed obsereved ( Not Acceptable)

Prepared By Verified By
Mateen Ahmad Khan Sachin Kumar Singh

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